U.S. patent application number 11/208462 was filed with the patent office on 2006-05-11 for system and method for fastening floor deck to semi-trailer cross members.
Invention is credited to Michael J. Blakely, Michael J. Comella, Michael T. Perkowski.
Application Number | 20060096187 11/208462 |
Document ID | / |
Family ID | 36314864 |
Filed Date | 2006-05-11 |
United States Patent
Application |
20060096187 |
Kind Code |
A1 |
Perkowski; Michael T. ; et
al. |
May 11, 2006 |
System and method for fastening floor deck to semi-trailer cross
members
Abstract
A cargo carrier includes a plurality of laterally extending and
longitudinally spaced-apart cross members, a plurality of
longitudinally extending decking extrusions supported on the cross
members and forming a cargo deck, and retainers securing the
decking extrusions to the cross members. The retainers limit or
substantially prevent vertical relative movement between the
decking extrusions and the cross members. The retainers permit
longitudinal relative movement between the decking extrusions and
the cross members and at least one end of the decking extrusions is
provided with a gap so that the decking extrusions can move in the
longitudinal direction to reduce shear stress at the decking
connections due to deflection of the decking extrusions, thermal
expansion and contraction of the decking extrusions, and the
like.
Inventors: |
Perkowski; Michael T.;
(Dover, OH) ; Blakely; Michael J.; (Dover, OH)
; Comella; Michael J.; (Dover, OH) |
Correspondence
Address: |
Porter, Wright, Morris & Arthur LLP;ATTN: Intellectual Property Department
28th Floor
41 South High Street
Columbus
OH
43215-6194
US
|
Family ID: |
36314864 |
Appl. No.: |
11/208462 |
Filed: |
August 19, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60625704 |
Nov 5, 2004 |
|
|
|
Current U.S.
Class: |
52/177 |
Current CPC
Class: |
E04F 2201/0517 20130101;
B62D 33/02 20130101; B62D 25/2054 20130101 |
Class at
Publication: |
052/177 |
International
Class: |
E04F 15/00 20060101
E04F015/00 |
Claims
1. A cargo carrier comprising, in combination: a plurality of
laterally extending and longitudinally spaced apart cross members;
a plurality of longitudinally extending decking extrusions
supported on the cross members and forming a cargo deck; retainers
securing the decking extrusions to the cross members; wherein the
retainers limit vertical relative movement between the decking
extrusions and the cross members; and wherein the retainers permit
longitudinal relative movement between the decking extrusions and
the cross members and at least one end of the decking extrusions is
provided with a gap so that the decking extrusions can move in the
longitudinal direction.
2. The cargo carrier according to claim 1, wherein said retainers
are extrusions.
3. The cargo carrier according to claim 1, wherein said retainers
are directly secured to the cross members.
4. The cargo carrier according to claim 1, wherein said retainers
form an interlock with flanges of the extrusions in the vertical
direction.
5. The cargo carrier according to claim 4, wherein said retainers
form an interlock with flanges of the extrusions in the lateral
direction.
6. The cargo carrier according to claim 1, wherein said retainers
are secured to the cross members with a snap fit connection.
7. The cargo carrier according to claim 1, wherein said decking
extrusions are secured to the retainers with a snap fit
connection.
8. The cargo carrier according to claim 1, wherein said retainers
each include separate first and second members, the first member is
secured to the decking extrusion, and the second member secures the
first member to the cross member.
9. The cargo carrier according to claim 8, wherein said first
members are secured to the decking extrusions with a snap fit
connection and the second members are secured to the cross members
with a snap fit connection.
10. The cargo carrier according to claim 8, wherein said first and
second members are each extrusions.
11. The cargo carrier according to claim 8, wherein said first and
second members are oriented 90 degrees one from the other.
12. The cargo carrier according to claim 1, further comprising
laterally extending end beams located at longitudinal ends of the
decking extrusions, end retainers securing the decking extrusions
to the end beams, the end retainers limit vertical relative
movement between the decking extrusions and the end beams, and
permit longitudinal relative movement between the decking
extrusions and the end beams.
13. The cargo carrier according to claim 1, wherein the retainers
limit lateral relative movement between the decking extrusions and
the cross members.
14. The cargo carrier according to claim 1, wherein the retainers
substantially prevent lateral relative movement between the decking
extrusions and the cross members.
15. A cargo carrier comprising, in combination: a plurality of
laterally extending and longitudinally spaced apart cross members;
a plurality of longitudinally extending decking extrusions
supported on the cross members and forming a cargo deck; retainers
securing the decking extrusions to the cross members; wherein the
retainers limit vertical relative movement between the decking
extrusions and the cross members; wherein the retainers permit
longitudinal relative movement between the decking extrusions and
the cross members and at least one end of the decking extrusions is
provided with a gap so that the decking extrusions can move in the
longitudinal direction wherein the retainers each include separate
first and second members, the first member is secured to the
decking extrusion with a snap-fit connection, and the second member
secures the first member to the cross member with a snap fit
connection; and wherein said first and second members are each
extrusions.
16. The cargo carrier according to claim 15, wherein said first and
second members are oriented 90 degrees one from the other.
17. The cargo carrier according to claim 15, wherein said first and
second members each comprise aluminum.
18. The cargo carrier according to claim 15, wherein said first
member is generally inverted-U-shaped in cross-section having a top
wall and a pair of side walls downwardly extending from edges of
the top wall, and a protrusion outwardly extending from each of the
sidewalls and interlocking with flanges of the decking
extrusions.
19. The cargo carrier according to claim 18, wherein said first
member also has a pair of legs downwardly extending from the top
wall between the side walls, and the legs have a vertical length
greater than the vertical length of the side walls.
20. The cargo carrier according to claim 15, wherein said second
member is generally inverted-U-shaped in cross-section having a top
wall and a pair of side walls downwardly extending from edges of
the top wall, and a protrusion inwardly extending from each of the
sidewalls and interlocking with flanges of the cross members.
21. The cargo carrier according to claim 15, further comprising
laterally extending end beams located at longitudinal ends of the
decking extrusions, end retainers securing the decking extrusions
to the end beams, the end retainers limit vertical relative
movement between the decking extrusions and the end beams, and
permit longitudinal relative movement between the decking
extrusions and the end beams.
22. A platform semi-trailer comprising, in combination: a plurality
of laterally extending and longitudinally spaced apart cross
members; a plurality of longitudinally extending decking extrusions
supported on the cross members and forming a cargo deck; retainers
securing the decking extrusions to the cross members; wherein the
retainers limit vertical relative movement between the decking
extrusions and the cross members; wherein the retainers permit
longitudinal relative movement between the decking extrusions and
the cross members and at least one end of the decking extrusions is
provided with a gap so that the decking extrusions can move in the
longitudinal direction; and wherein said retainers each include
separate first and second members, the first member is secured to
the decking extrusion with a snap-fit connection, and the second
member secures the first member to the cross member with a snap fit
connection.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority benefit of U.S. Provisional
Patent Application No. 60/625,704 filed on Nov. 5, 2004, the
disclosure of which is expressly incorporated herein in its
entirety by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
REFERENCE TO MICROFICHE APPENDIX
[0003] Not Applicable
FIELD OF THE INVENTION
[0004] The present invention generally relates to floor deck of
cargo carriers such as, for example, semi-trailers and the like
and, more particularly, relates to systems for securing such floor
deck to its underlying support structure.
BACKGROUND OF THE INVENTION
[0005] Current platform semi-trailers are constructed using a beam
and cross member structural system. Two main beams typically span
the longitudinal length of the platform (usually forty eight feet)
and cross members typically span the transverse width of the
platform (usually eight feet or eight feet and six inches). The
cross members typically have a spacing of six to twenty-four
inches. The main beams and the cross members cooperate to create a
grid or support structure for supporting the floor deck of the
platform. The floor deck is typically secured to the cross
members.
[0006] Two categories of platforms are currently produced.
Composite platforms have steel main beams and steel or aluminum
cross members. Aluminum platforms have aluminum main beams and
aluminum cross members.
[0007] The floor deck usually includes wood boards, extruded
aluminum decking, or a combination of the two. The majority of
currently produced platforms utilize extruded aluminum decking with
two to four wood boards (typically referred to as "nailers"). The
extruded aluminum decking is nearly as long as the platform.
Currently, there are two categories of extruded aluminum decking:
T-style decking; and multi-hollow decking. T-style decking has two
subcategories that may be called nail type and screw type.
[0008] As shown in FIGS. 1 and 2, Nail type, T-style decking 10 is
fastened to the cross members 12 with powder actuated nails 14. The
nails 14 penetrate an upper surface of the extruded aluminum
decking 10, pass through a void, and penetrate an upper flange 16
of the cross member 12. The faying surface is separated in this
type of connection.
[0009] As shown in FIGS. 3 and 4, screw type, T-style decking 10 is
fastened to the cross members 12 with screws 18. The screws 18
penetrate the upper surface of the extruded aluminum decking 10 and
penetrate the upper flange 16 of the cross member 12. The faying
surface is not separated in this type of connection.
[0010] As shown in FIGS. 5, and 6, multi-hollow decking is
typically used only with aluminum cross members 12. A bottom face
of the extruded aluminum decking 10 is welded to the upper flange
16 of the cross member 12 with a fillet weld 19. The fillet weld 19
can be nearly the full width of the extruded aluminum decking 10.
The faying surface is not separated in this type of connection.
[0011] The primary function of the connection between the floor
deck and the cross members is to prevent vertical separation of the
floor deck from the platform trailer. Side rails are welded or
bolted to ends of the cross members to prevent the floor deck from
sliding laterally and separating from the platform trailer. Front
and rear ends of the floor deck are enclosed by trailer framing in
order to prevent longitudinal separation of the floor deck from the
platform trailer.
[0012] Many factors contribute to longitudinal movement of the
floor deck relative to the cross members. Temperature changes cause
the long extruded aluminum decking to expand or contract and change
length. Deflection of the main beams force the extruded aluminum
decking to bend and move relative to the cross members. This
longitudinal movement causes shear forces to occur at the
connections of the floor deck. Severe prying forces can be
developed when the faying surfaces are separated from the cross
members. Due to the long length of the floor deck, these shear
forces due to longitudinal movement of the floor deck are much
greater than shear forces due to lateral movement of the floor
deck. These shear forces due to longitudinal movement can
eventually cause the connections to fail. Accordingly, there is a
need in the art for an improved system and method for fastening
floor deck of a cargo carrier.
SUMMARY OF THE INVENTION
[0013] The present invention provides a system and method for
fastening floor deck of a cargo carrier which overcomes at least
some of the above-noted problems of the related art. According to
the present invention, a cargo carrier comprises, in combination, a
plurality of laterally extending and longitudinally spaced apart
cross members, a plurality of longitudinally extending decking
extrusions supported on the cross members and forming a cargo deck,
and retainers securing the decking extrusions to the cross members.
The retainers limit vertical relative movement between the decking
extrusions and the cross members. The retainers permit longitudinal
relative movement between the decking extrusions and the cross
members and at least one end of the decking extrusions is provided
with a gap so that the decking extrusions can move in the
longitudinal direction.
[0014] According to another aspect of the present invention, a
cargo carrier comprises, in combination, a plurality of laterally
extending and longitudinally spaced apart cross members, a
plurality of longitudinally extending decking extrusions supported
on the cross members and forming a cargo deck, and retainers
securing the decking extrusions to the cross members. The retainers
limit-vertical relative movement between the decking extrusions and
the cross members. The retainers permit longitudinal relative
movement between the decking extrusions and the cross members and
at least one end of the decking extrusions is provided with a gap
so that the decking extrusions can move in the longitudinal
direction. The retainers each include separate first and second
members, the first member is secured to the decking extrusion with
a snap-fit connection, and the second member secures the first
member to the cross member with a snap fit connection. The first
and second members are each extrusions.
[0015] According to yet another aspect of the present invention, a
platform semi-trailer comprises, in combination, a plurality of
laterally extending and longitudinally spaced apart cross members,
a plurality of longitudinally extending decking extrusions
supported on the cross members and forming a cargo deck, and
retainers securing the decking extrusions to the cross members. The
retainers limit vertical relative movement between the decking
extrusions and the cross members. The retainers permit longitudinal
relative movement between the decking extrusions and the cross
members and at least one end of the decking extrusions is provided
with a gap so that the decking extrusions can move in the
longitudinal direction. The retainers each include separate first
and second members, the first member is secured to the decking
extrusion with a snap-fit connection, and the second member secures
the first member to the cross member with a snap fit
connection.
[0016] From the foregoing disclosure and the following more
detailed description of various preferred embodiments it will be
apparent to those skilled in the art that the present invention
provides a significant advance in the technology and art of systems
and methods for fastening floor deck of cargo carriers.
Particularly significant in this regard is the potential the
invention affords for providing a high quality, reliable, low cost
assembly with rapid assembly time. Additional features and
advantages of various preferred embodiments will be better
understood in view of the detailed description provided below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and further features of the present invention will be
apparent with reference to the following description and drawings,
wherein:
[0018] FIG. 1 is a fragmented, end elevational view of prior art
floor deck secured with nails to cross members of a
semi-trailer;
[0019] FIG. 2 is a fragmented, side elevational view of the prior
art floor deck of FIG. 1;
[0020] FIG. 3 is a fragmented, end elevational view of prior art
floor deck secured with screws to cross members of a
semi-trailer;
[0021] FIG. 4 is a fragmented, side elevational view of the prior
art floor deck of FIG. 3;
[0022] FIG. 5 is a fragmented, end elevational view of prior art
floor deck secured with fillet welds to cross members of a
semi-trailer;
[0023] FIG. 6 is a fragmented, side elevational view of the prior
art floor deck of FIG. 5;
[0024] FIG. 7 is a top plan view of floor deck of a semi-trailer
which has been retrofitted with retainers or lock members securing
the floor deck to cross members according to a first embodiment of
the present invention;
[0025] FIG. 8 is an end elevational view of the floor deck of FIG.
7, wherein some components are removed for clarity;
[0026] FIG. 9 is an enlarged, fragmented, end elevational view of
the floor deck of FIGS. 7 and 8 showing the lock members;
[0027] FIG. 10 is an enlarged, fragmented, side elevational view of
the floor deck of FIGS. 7 to 9 showing the lock members;
[0028] FIG. 11 is a side elevational view similar to FIG. 10 but
showing a variation of the lock members;
[0029] FIG. 12 is an end elevational view similar to FIG. 9, but
showing floor deck with retainers or lock members securing the
floor deck to cross members according to a second embodiment of the
present invention;
[0030] FIG. 13 is a side elevational view of the floor deck of FIG.
12 showing the lock members;
[0031] FIG. 14 is a side elevational view similar to FIG. 13 but
showing a variation of the lock members;
[0032] FIG. 15 is an end elevational view similar to FIGS. 9 and
12, but showing floor deck with retainers or lock members securing
the floor deck to cross members according to a third embodiment of
the present invention;
[0033] FIG. 16 is a side elevational view of the floor deck of FIG.
15 showing the lock members;
[0034] FIG. 17 is an enlarged, end elevational view of the floor
deck of FIGS. 15 and 16;
[0035] FIG. 18 is an end elevational view of an outer member of the
lock members of FIGS. 15 and 16;
[0036] FIG. 19 is a side elevational view of the outer member of
FIG. 18;
[0037] FIG. 20 is an end elevational view of an inner member of the
lock members of FIGS. 15 and 16;
[0038] FIG. 21 is a side elevational view of the inner member of
FIG. 20;
[0039] FIG. 22 is an end elevational view similar to FIGS. 9, 12
and 15, but showing floor deck with retainers or lock members
securing the floor deck to cross members according to a fourth
embodiment of the present invention;
[0040] FIG. 23 is a side elevational view of the floor deck of FIG.
22 showing the lock members;
[0041] FIG. 24 is an end elevational view of an inner member of the
lock members of FIGS. 22 and 24;
[0042] FIG. 25 is a side elevational view of the inner member of
FIG. 24;
[0043] FIG. 26 is a side elevational view similar to FIG. 25 but
showing a variation of the inner member;
[0044] FIG. 27 is an end elevational view showing floor deck with
retainers or lock members securing the floor deck to an end beam
according to the present invention;
[0045] FIG. 28 is a side elevational view of the floor deck of FIG.
27 showing the lock members;
[0046] FIG. 29 is an end elevational view of an outer member of the
lock members of FIGS. 27 and 28; and
[0047] FIG. 30 is a side elevational view of the outer member of
FIG. 29.
[0048] It should be understood that the appended drawings are not
necessarily to scale, presenting a somewhat simplified
representation of various preferred features illustrative of the
basic principles of the invention. The specific design features of
the system and method for fastening floor deck of a cargo carrier
as disclosed herein, including, for example, specific dimensions,
orientations, locations, and shapes of the various components, will
be determined in part by the particular intended application and
use environment. Certain features of the illustrated embodiments
have been enlarged or distorted relative to others to facilitate
visualization and clear understanding. In particular, thin features
may be thickened, for example, for clarity or illustration. All
references to direction and position, unless otherwise indicated,
refer to the orientation of the system and method for fastening
floor deck of a cargo carrier illustrated in the drawings. In
general, up or upward generally refers to an upward direction
within the plain of the paper in FIGS. 1, 5, 8, 11, 18, and 22 and
down or downward generally refers to a downward direction within
the plane of the paper in FIGS. 1, 5, 8, 11, 18, and 22. Also in
general, fore or forward refers to a direction toward the front of
the cargo carrier, that is, generally toward the right within the
plane of the paper in FIG. 7 and aft or rearward refers to a
direction toward the rear of the cargo carrier, that is, generally
toward the left within the plane of the paper in FIG. 7. Also in
general, lateral or transverse refers to a side to side direction
of the cargo carrier, that is, generally up and down within the
plane of the paper in FIG. 7.
DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS
[0049] It will be apparent to those skilled in the art, that is, to
those who have knowledge or experience in this area of technology,
that many uses and design variations are possible for the improved
system and method for fastening floor deck of a cargo carrier
disclosed herein. The following detailed discussion of various
alternative and preferred embodiments will illustrate the general
principles of the invention with reference to a system and method
for fastening floor deck of a cargo carrier such as a platform
semi-trailer. Other embodiments suitable for other applications,
such as any other suitable type of trailers, trucks, locomotive
cars, ships, planes, and the like having decking supported by
structural members will be apparent to those skilled in the art
given the benefit of this disclosure.
[0050] Referring now to the drawings, FIGS. 7 to 10 illustrate a
system and method for fastening floor deck according to a preferred
embodiment of the present invention. The illustrated cargo carrier
20 has been retrofitted according to the present invention so that
the nail type decking 10 is secured by a plurality of inserts or
retainers 21 in addition to the nails 14 which initially secured
the decking 10. Retrofitted in the manner, the retainers 21 secure
the decking 10 in a desired manner even if the nails 14 fail or
have failed due to shear stress created by longitudinal movement of
the decking 10. This cargo carrier 20 illustrates that existing
fleets can be retrofitted to obtain benefits of the present
invention. It is noted that the cargo carrier 20 can alternatively
be newly constructed according to the present invention wherein the
nails 14 are not needed and can be eliminated if desired.
[0051] The illustrated cargo carrier 20 includes a pair of parallel
and laterally spaced-apart main beams 22. The illustrated main
beams 22 span the longitudinal length of the cargo carrier 20. The
illustrated longitudinal length is about 48 feet but any other
suitable length can be utilized. The illustrated main beams 22 are
I-beams having, in cross-section a main web or wall 24 and upper
and lower flanges 26, 28 at the top and bottom of the main web. It
is noted that the main beams 22 can alternatively have any other
suitable shape. The main beams 22 can comprise any suitable
material such as, for example, steel, aluminum, or the like.
[0052] A plurality of parallel and longitudinally spaced-apart
cross members 12 are secured to the main beams 22 to create a grid
or support structure for supporting the floor deck or decking 10.
The cross members 12 can be secured to the main beams 22 in any
suitable manner. The illustrated cross members 12 span the
transverse width of the platform which is preferably about eight
feet to about eight feet and six inches. The cross members
preferably have a longitudinal spacing of about six to about
twenty-four inches but any other suitable spacing can be utilized.
The illustrated cross-members 12 are I-beams having, in
cross-section a main web or wall 30 and upper and lower flanges 16,
32 at the top and bottom of the main web 30. It is noted that the
cross members 12 can alternatively have any other suitable shape.
The cross members 12 can comprise any suitable material such as,
for example, steel, aluminum, or the like. The decking 10 is
secured to the cross members 12 as described in more detail
hereinafter. The illustrated cross members 12 are positioned at a
height below the upper flanges 26 of the main beams 22 so that the
top surfaces of the decking 10 are generally flush with the main
beam upper flanges 26. It is noted, however, that the cross members
12 can alternatively be positioned relative to the main beams 22 in
any other suitable manner.
[0053] The illustrated cargo carrier 20 includes side rails 34
secured to the ends of the cross members 12. The illustrated side
rails 34 extend the longitudinal length of the cargo carrier 20.
The side rails 34 can be secured to the cross members 12 in any
suitable manner such as, for example, welding, mechanical
fasteners, or the like. The side rails 34 can comprise any suitable
material such as, for example, steel, aluminum, or the like. The
illustrated side rails 34 are generally C-shaped in cross-section
and receive the ends of the cross members 12 therein so that upper
surfaces of the side rails 34 are generally flush with the decking
10 and the main beam upper flanges 26. The illustrated side rails
34 have a plurality of longitudinally spaced-apart stake pockets 36
secured to an outer side thereof and rub rails secured to the outer
sides of the stake pockets 36. The stake pockets 36 and the rub
rails 38 can be secured in any suitable manner such as, for
example, welding, mechanical fasteners, or the like. The stake
pockets 36 and the rub rails 38 can comprise any suitable material
such as, for example, steel, aluminum, or the like.
[0054] The illustrated cargo carrier 20 includes end or nose and
tail beams 40 secured to the ends of the main beams 22. The
illustrated nose and tail beams 40 extend the entire lateral width
between the side rails 34 of the cargo carrier 20. The nose and
tail beams 40 can be secured to the main beams 22 and the side
rails 34 in any suitable manner such as, for example, welding,
mechanical fasteners, or the like. The nose and tail beams 40 can
comprise any suitable material such as, for example, steel,
aluminum, or the like. The illustrated nose and tail beams 40 are
positioned so that upper surfaces of the nose and tail beams 40 are
generally flush with the decking 10 and the main beam upper flanges
26.
[0055] The deck or floor of the illustrated cargo carrier 20 is
formed by the two main beam upper flanges 26, two wood nailers 42,
the top surfaces of the side rails 34, and eleven extrusions of the
decking 10. It is noted that alternatively any other suitable
combination and/or quantities can be utilized such as, for example,
a greater or fewer number of the nailers 42 can be utilized and/or
the nailers 42 could be eliminated. The illustrated main beam upper
flanges 26, wood nailers 42, side rails 34, and decking 10 extend
the entire longitudinal length between the nose and tail beams 40
and are positioned side by side to form a generally continuous
upper surface for supporting cargo thereon. The nailers 42 can be
secured to the cross members 12 in any suitable manner such as, for
example, mechanical fasteners like screws or the like. The nailers
42 can comprise any suitable material such as, for example, wood or
the like.
[0056] The illustrated decking 10 are aluminum extrusions but it is
noted that the decking can alternatively be formed in any other
suitable manner and can comprise any other suitable material. The
illustrated decking 10 includes, in cross-section, a
horizontally-extending top flange 44, a plurality of
vertically-extending support webs or walls 46 spaced-apart along
the width of the top flange 44 to form a plurality of pockets, and
a plurality of horizontally extending bottom flanges 48 at the
lower ends of the support walls 46 to support the decking 10 on the
cross members 12. The illustrated decking 10 includes seven support
walls 46 that form six pockets including a pair of outer pockets
50, a pair of intermediate pockets 52, and a pair of inner pockets
54. It is noted that any other suitable number of support walls 46
can alternatively be utilized to form any other suitable number of
pockets.
[0057] The illustrated decking is supported on the cross members 12
with the flanges 48 directly engaging the upper flange 16 of the
cross members 12. The illustrated decking 10 is secured to the
cross members 12 by the nails 14 which extend through the top
flange 44 and the intermediate pockets 52, to the upper flange 16
of the cross members. Such connections are typically provided for
each of the decking 10 at each of the cross members 12. It is noted
that the nails 14 are present because the illustrated embodiment is
a retrofit of an existing cargo carrier 20 already having nails 14
present and it is not necessary to remove the nails 14. It should
be appreciated that the nails 14 can be eliminated in a new
construction and/or retrofit if desired.
[0058] The illustrated decking 10 is also secured to the cross
members 12 by the inserts or retainers 21. The illustrated decking
10 is secured by two of the retainers 21 at each of the cross
members 12. It is noted, however, that other suitable quantities
and locations of the retainer 21 can alternatively be utilized. The
illustrated retainers 21 are sized and shaped to extend into the
inner pockets 54 of the decking 10 and interlock with the flanges
48 of the decking 10 at the inner pockets 54. It is noted, however,
that other suitable sizes and shapes can alternatively be utilized.
The illustrated retainers 21 have a rectangular-shaped main body 56
and left and right upper flanges 58, 60 which are sized to
laterally extend over the decking flanges 48 when the retainer 21
is engaging the upper flange 16 of the cross member 12. The
illustrated retainers 21 longitudinally extend over edges of the
cross member upper flanges 16 in a cantilevered manner and are
secured to the cross members 12 by a fillet weld 61. It is noted,
however, that the retainers 21 can be secured to the cross members
12 in any other suitable manner such as, for example, mechanical
fasteners, adhesives, snap-fit connections, or the like. The
illustrated retainers 21 are aluminum extrusions but it is noted
that the retainers 21 can alternatively be formed in any other
suitable manner and can comprise any other suitable material.
[0059] The retainer flanges 58, 60 are sized to engage the decking
flanges 48 to limit or substantially prevent vertical movement of
the decking 10 relative to the cross member 12, to limit or
substantially prevent lateral movement of the decking 10 relative
to the cross-member 12, and to freely permit longitudinal movement
of the decking 10 relative to the cross member. It is noted that
while the illustrated retainers 21 allow unlimited longitudinal
movement of the decking 10 relative to the cross members 12, the
decking 10 is retained to the cargo carrier 20 in the longitudinal
direction by the nose and tail beams. Suitable gaps 62 are provided
between the decking 10 and the nose and tail beams 40 to permit
longitudinal movement of the decking 10 as needed to substantially
reduce and/or eliminate shear stress in the decking connection due
to longitudinal movement of the decking 10. The illustrated gaps 62
are each about 3/16 of an inch. The gaps 62 are preferably provided
at both ends of the decking 10 but alternatively can be provided at
only one of the longitudinal ends. Thus, the retainers 21 are
rigidly secured to the cross members 12 and are interlocked with
the decking 10 to secure the decking 10 to the cross members 12 in
a manner which permits the decking 10 to freely move in the
longitudinal direction relative to the cross members 12 while
limiting and/or substantially preventing the decking 10 from moving
in the vertical direction relative to the cross members 12 and
limiting or substantially preventing the decking 10 from moving in
the lateral direction relative to the cross members 12. It is noted
that illustrated adjacent ones of the decking 10 are not secured
together other than through the separate retainers 21 and the cross
members 12 to allow the decking 10 to independently move. It is
also noted that the illustrated ones of the retainers 21 are not
secured together and each retainer engages and secures only one of
the decking extrusions 10.
[0060] FIG. 11 illustrates a variation of the retainers 21 of the
first embodiment, wherein the retainers 21 longitudinally extend
over both edges of the cross member upper flanges 16 in a
cantilevered manner and are secured to the cross members 12 by
fillet welds 61 at each edge of the cross members 12. It is
believed that this variation provides a stronger connection between
the retainers 21 and the cross members 12.
[0061] FIGS. 12 and 13 illustrate a second embodiment of the
present invention. This second embodiment is substantially the same
as the first embodiment described above except as describe below
and like reference numbers are used to indicate like structure. The
second embodiment illustrates that cargo carrier 20 can be a new
construction rather than a retrofit so that the nails 14 or other
deck fasteners are not present, that the decking 10 can have other
suitable shapes and sizes and that the retainers 21 can have other
suitable shapes and sizes. The illustrated decking 10 of the second
embodiment has four support walls 46 that form three pockets
including a pair of outer pockets 50, and a single inner pocket 54.
It is noted that any other suitable number of support walls 46 can
alternatively be utilized to form any other suitable number of
pockets. The illustrated decking 10 is secured by a single one of
the retainers 21 at each of the cross members 12 and located in the
inner pocket 54. It is noted, however, that other quantities of the
retainer 21 can alternatively be utilized. The retainer 21 and the
decking flanges 48 are also shaped to form a lateral interlock in
addition to the vertical interlock. The illustrated lateral
interlock is formed by the retainer left and right flanges 58, 60
being provided with downwardly extending flange portions 64 at
their outer edges and the decking flanges 48 being provided with
upwardly-extending flange portions 66 at their inner edges.
[0062] FIG. 14 illustrates a variation of the retainers 21 of the
second embodiment, wherein the retainers 21 longitudinally extend
over both edges of the cross member upper flanges 16 in a
cantilevered manner and are secured to the cross members 12 by
fillet welds 61 at each edge of the cross members 12. It is
believed that this variation provides a stronger connection between
the retainers 21 and the cross members 12.
[0063] FIGS. 15 to 21 illustrate a third embodiment of the present
invention. This third embodiment is substantially the same as the
first and second embodiments described above except as described
below and like references numbers are used to indicate like
structure. The third embodiment illustrates that the decking 10 can
have other suitable shapes and sizes and that the retainers 21 can
have other suitable shapes and sizes. The illustrated decking 10 of
the third embodiment has seven support walls 46 that form six
pockets including a pair of outer pockets 50, a pair of
intermediate pockets 52, and a pair of inner pockets 54. It is
noted that any other suitable number of support walls 46 can
alternatively be utilized to form any other suitable number of
pockets. The outermost support walls 46 are also sized and shaped
so that adjacent decking 10 overlap in the lateral direction. The
illustrated decking 10 is secured by a pair of the retainers 21 at
each of the cross members 12 and located in the intermediate
pockets 52. It is noted, however, that other quantities and
locations of the retainer 21 can alternatively be utilized.
[0064] The illustrated retainers 21 of the third embodiment
comprise a first or lower member 68 and a separate second or upper
member 70. It is noted, however, that these retainers 21 with the
snap-fit connections described below can alternatively be formed as
a single component or more components. The illustrated first
retainer member 68 is sized and shaped to be secured to the decking
flanges 48 with a snap-fit connection while the second member 70 is
sized and shaped to be secured to the cross-member 12 with a
snap-fit connection while retaining the first retainer member 68 to
the cross member 12. The term "Snap-fit connection" is used in this
specification and the claims to mean a connection between two
separate components wherein the two components are moved toward one
another during assembly such that at least a portion of one or both
of the components resiliently deflects as the components are
brought together to eliminate an interference therebetween and
resiliently reestablish the interference once the components are
moved past the interference to secure the components together in
the direction of the interference. The illustrated first member 68
is generally inverted-U-shaped in cross-section having a top wall
72 and a pair of side walls 74 downwardly extending from outer
edges of the top wall 72. Protrusions 76 are provided at the
outside of the lower end of the side walls 74. The protrusions 76
are sized and shaped to cooperate with the flanges 48 of the
decking 10 to limit and/or prevent vertical movement of the decking
10 relative to the cross member 12. The illustrated first members
68 are aluminum extrusions but it is noted that the first members
68 can alternatively be formed in any other suitable manner and can
comprise any other suitable material.
[0065] The illustrated second member 70 is generally
inverted-U-shaped in cross-section having a top wall 78 and a pair
of side walls 80 downwardly extending from outer edges of the top
wall 78. Inwardly-extending protrusions 82 are provided at the
inside of the lower end of the side walls 80. The protrusions 82
are sized and shaped to cooperate with the upper flange 16 of the
cross member to limit and/or prevent vertical and longitudinal
movement of the second member 70 relative to the cross member 12.
Because the second member 70 is sized to closely extend over the
first member 68, this also limits and/or prevents vertical and
longitudinal movement of the first member 68 relative to the cross
member 12. The outer sides of the first member top wall 72 is
provided with protrusions or flanges 84 sized and shaped to limit
and/or prevent lateral relative movement between the first and
second members 68, 70. The second members 70 have a length that
closely fits between the flanges 84 within the first member 68. The
illustrated second members 70 are aluminum extrusions but it is
noted that the second members 70 can alternatively be formed in any
other suitable manner and can comprise any other suitable
material.
[0066] The decking 10 is preferably installed by first securing the
retainers 21 to the cross members 12 by snapping the second members
70 onto the cross members 12 over the first members 68. The second
members are oriented 90 degrees to the first members. As the second
members 70 are forced downwardly over the upper flange 16 of the
cross member 12, the side walls 80 deflect outwardly so that the
protrusions 82 pass over the upper flange 16 and then resiliently
snap back once the protrusions 82 are located below the upper
flange 16 to form a vertical interlock between the second member 70
and the cross member 12. It is noted that the lower side of the
illustrated protrusions 82 are provided with an angled camming
surface 86 to ease installation of the second members 70. The
decking 10 is then snapped onto the first members 68. As the
decking 10 is forced downwardly over the retainers 21, the support
walls 46 adjacent the retainers 21 deflect outwardly so that the
flanges 48 pass over the protrusions 76 and then resiliently snap
back once the flanges 48 are located below the protrusions 76 to
form a vertical interlock between the first member 68 and the
decking 10. It is noted that the side walls 74 may also resiliently
deflect inwardly as the flanges 48 pass the protrusions 76. It is
noted that the lower side of the illustrated flanges 48 are
provided with an angled camming surface 88 to ease installation of
the decking. It is also noted that the upper side of the
illustrated protrusions 76 are provided with an angled camming
surface 90 to further ease installation of the decking 10.
Installed in this manner, the decking 10 can be quickly installed
by the retainers 21 without the use of mechanical fasteners or
welds to obtain the desired connection that freely permits
longitudinal movement of the decking 10 relative to the cross
members 12 as described hereinabove.
[0067] FIGS. 22 to 25 illustrate a fourth embodiment of the present
invention. This fourth embodiment is substantially the same as the
third embodiment described hereinabove except as described
hereinbelow and like references numbers are used to indicate like
structure. The fourth embodiment illustrates that the decking 10
can alternatively have other suitable shapes. The fourth embodiment
also illustrates the first member 68 of the retainer 21 can have
other suitable shapes and sizes. The illustrated first member 68 of
the fourth embodiment includes a pair of laterally spaced-apart
legs or walls 92 downwardly extending from the top wall 72 between
the side walls 74. The illustrated legs 92 are substantially
parallel to one another and the side walls 74. The lower end of the
illustrated legs are provided with flanges 94 to support the first
member 68 on the cross member upper flange 16. The legs 92
preferably have a vertical length which is greater than the
vertical length of the side walls 74 (shown at 95) so that the side
walls 74 more easily deflect in an inward direction during
installation of the decking over the retainers 21 and thus reducing
the force required to resiliently snap the decking 10 onto the
retainers 21.
[0068] FIG. 26 illustrates a variation of the inner member 68 of
the fourth embodiment, wherein the lower inner edge of the side
walls 74 are provided with an angled surface or chamfer 96, the
lower end of the legs 92 are rounded 93 and an offset 97 is
provided between the outer surface of the side walls 74 above the
protrusions 76 and the outer surface of the side walls 74 below the
protrusions 76. The angled surface or chamfer 96 helps to reduce
the weight of the inner member 68. The rounded ends of the legs 92
aid the lateral movement of the inner member 68 when the decking 10
is being installed. The offset 97 allows for easier engagement of
the retainer 21 by the decking 10 during installation.
[0069] FIGS. 27 to 30 illustrate that the decking 10 can also be
secured to the nose and tail beams 40 using snap-fit retainers 98
similar to the retainers 21 securing the decking 10 to the cross
members 12 as described above. The illustrated retainers 98 include
a first or lower member 68 substantially the same as that described
above and a second or outer member 100. The illustrated outer
member 100 is generally lazy or sideways U-shaped in cross-section
having a side wall 102 and upper and lower walls 104, 106 outwardly
extending from upper and lower edges of the side wall 102.
Inwardly-extending protrusions 108 are provided at the inside of
the outer ends of the upper and lower walls 104, 106. The
protrusions 108 are sized and shaped to cooperate with the top wall
72 of the first member 68 and a flange 110 of the nose or tail beam
40 to limit and/or prevent vertical and longitudinal movement of
the second member 100 relative to the nose or tail beam 40. Because
the second member 100 is sized to closely extend over the first
member 68, this also limits and/or prevents vertical and
longitudinal movement of the first member 68 relative to the nose
or tail beam 40. The flanges 84 of the first member top wall 72
limit and/or prevent lateral relative movement between the first
and second members 68, 100. The second members 100 have a length
that closely fits between the flanges 84 within the first member
68. The illustrated first and second members 68, 100 are aluminum
extrusions but it is noted that the they can alternatively be
formed in any other suitable manner and can comprise any other
suitable material. The retainer is installed in a manner similar to
the method described hereinabove with regard to the retainer 21 for
the cross members 12.
[0070] From the foregoing disclosure and detailed description of
certain preferred embodiments, it is also apparent that various
modifications, additions and other alternative embodiments are
possible without departing from the true scope and spirit of the
present invention. The embodiments discussed were chosen and
described to provide the best illustration of the principles of the
present invention and its practical application to thereby enable
one of ordinary skill in the art to utilize the invention in
various embodiments and with various modifications as are suited to
the particular use contemplated. All such modifications and
variations are within the scope of the present invention as
determined by the appended claims when interpreted in accordance
with the benefit to which they are fairly, legally, and equitably
entitled.
* * * * *